Piezo Actuator Closure Means for 3D Printing
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Solution Overview
Problem
Current methods for producing small batch sizes of plastic parts with complex geometries face challenges in maintaining precise control over droplet size and frequency, leading to reduced service life and increased costs due to the delicate balance of forces and thermal expansion in high-pressure, high-temperature conditions.
Innovation Solution
A control unit and regulation system that creates a characteristic map to adjust and maintain the elastic working range of the closure means, allowing for precise operation and wear-free continuous discharge by measuring and adjusting the elastic properties of the closure means using a piezo actuator, ensuring reliable operation within the elastic range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pressure (up to 200 MPa) and high temperature (up to 450°C) are used to discharge viscous fluid through a small nozzle (diameter around 0.1 mm), then droplet size can be reduced to 0.001 mm³ for good surface quality, but the service life of the closure means is reduced due to the delicate balance of forces and thermal expansion
Solution Approach 1:
The patent implements dynamic adjustment of the contact pressure between the actuator and closure means by continuously monitoring the actual contact pressure and comparing it with the optimal value from the characteristic map. The actuator position is dynamically corrected to maintain optimal contact pressure, allowing the system to adapt to thermal expansion and wear during operation, thereby extending service life while maintaining precise droplet size control
Solution Approach 2:
The patent employs a feedback control system where the actual contact pressure is continuously measured and compared with the optimal contact pressure determined from the characteristic map. Based on this feedback, the actuator position is adjusted to maintain optimal operating conditions, ensuring both precise droplet discharge and extended service life of the closure means under high-pressure and high-temperature conditions
2Reliability
If the stroke of the actuator is increased to compensate for manufacturing tolerances and thermal expansion, then the elastic working range of the closure means is exceeded, but the contact pressure becomes unstable causing unwanted material escape or nozzle failure to open
Solution Approach 1:
The patent performs preliminary determination of the characteristic map for the closure means under various operating conditions before actual operation. This pre-characterization allows the system to know the optimal contact pressure and actuator position for each operating condition, enabling precise control without needing excessive stroke to compensate for tolerances and thermal expansion
Solution Approach 2:
The patent changes the operating parameters (contact pressure, temperature, pressure conditions) systematically to create a characteristic map that defines the optimal operating range. During operation, the system adjusts the actuator position within this predefined optimal range rather than using large strokes, maintaining stable contact pressure and preventing both material escape and nozzle failure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach extends the service life of the closure means and maintains consistent droplet size and frequency, enabling efficient production of three-dimensional objects with improved surface quality and reduced material waste.
Implementation Method 1
the actuator (26) for the closure means (24) when the closure means (24) is in operation
Implementation Method 2
a characteristic map (89) for an elastic deformation of the closure means (24) by means of the actuator (26) actuated by a setting unit (SV) is recorded
Implementation Method 3
the adhesive forces of the material requiring high pressure in the range of up to 200 MPa
Implementation Method 4
this material is discharged through an outlet opening (20) in the form of drops (15)
Data Source
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AI summary
In a method and a device for producing a three-dimensional object (16) from solidifiable material, which in the initial stage is present in the fluid phase or can be liquefied, by means of sequentially discharging drops (15) from at least one material reservoir (12) that can be pressurized for the fluid phase by means of at least one discharge unit (13) through an outlet opening (20) provided with a closure means (24) that can be cycled, the closure means is actuated by means of an actuator (26) and the preload thereof at the operating point is measured by means of the actuator (26). The preload is controlled by means of an actuating unit (SV). By means of the actuator (26) that is actuated by the actuating unit (SV), a characteristic map for the elastic deformation of the closure means (24) is acquired. Within the characteristic map, a resilient working range of the closure means (24) is set by means of the actuating unit (SV). Thus, a method and a device are provided, by means of which the closure means on such an apparatus can be operated as gently and therefore for as long as possible.